Broil King Baron/Regal Pellet Grills in 2020 – Features and Reviews


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Hi, I’m Chris I started PelHeat.com back in 2007.

Broil King has been making BBQs since the 1980s. However, they are not a well-established brand in the pellet grill market for the reason being they only started to produce pellet grills in 2019. However, after researching the Broil King Baron and Regal pellet grills I must admit I’m pretty impressed. The build quality, materials and features included in the Broil King pellet grills at their target price point does make than a valid consideration/alternative to more established pellet grills from say Traeger or Camp Chef. So with this post, I’m going to run through the features of the Broil King Baron and Regal pellet grills. At the same time highlighting features which I think help the Broil King pellet grills stand out, in a good way.

Broil King Pellet Grills/Smokers
While Broil King may be new to making pellet grills, I do think they have produced some very promising products with their Baron and Regal grills: Image – BBQGuys.comOpens in a new tab.

Disclaimer: Hey! By the way… any links on this page that lead to products on Amazon or other sites are affiliate links and I earn a commission if you make a purchase.

I recently wrote a post about Weber’s first attempts at producing pellet grills/smokers with the Weber SmokeFire. Unfortunately, the first generation of SmokeFire grills do appear to have issues which Weber need to go back to the drawing board to address. Therefore, when I became aware that Broil King also wished to enter the pellet grill market I was curious how they would fair. Would they be able to produce pellet grills right out of the gate which could compete with established pellet grill/smoker brands? Well, the early signs are looking very positive.

Both the Broil King Baron and Regal are mid-range pellet grills, sometimes referred to as ‘Practical Grills’. If you are not aware of the different pellet grill classes I have a post on how to choose the best pellet grill to meet your needs. The Baron and Regal pellet grills are not budget products, but they are also not aimed to compete with luxury pellet grills either such as the Traeger Timberline. They are targeted as your middle of the road grills for the average guy or girls back yard cooking needs.

Introduction To Broil King Pellet Grills

Broil King is marketing their pellet grills as being capable of both ‘low and slow’ cooking/smoking and high temperature searing. For instance, both the Broil King Baron and Regal pellet grills have a peak cooking temperature of 600 degrees. A cooking temperature that high is not often found on many pellet grills, particularly at this mid-range price point. There are several other features on these pellet grills which are also not commonly found on competing products which I’ll discuss more below. First, I wanted to include a promotional video from Broil King to quickly show you some of the features of these pellet grills.

Broil Kings short promotional video highlights the stand-out features of their pellet grills: Video – broilkingbbq.com

The video above is actually of the Broil King Regal which is the higher-spec model and it shows a couple of features which are not found on the cheaper Baron pellet grills. Therefore below, I’ve also included a second video from Broil King discussing the specific features of their Baron entry-level pellet grills.

The cheaper Baron pellet grills use a different control panel and do not come with the rotisserie kit, though it can be fitted when purchased separately: Video – broilkingbbq.com

Baron and Regal Pellet Grill Cooking Areas

The Baron is the lower-priced option of the two, with the Regal benefiting from a few additional features. In terms of the cooking area, there are a couple of pellet grill models under each specification. Even though the Baron grills have the same width as the Regal units, the additional depth on the Regal grills provides for extra cooking area:

  • Broil King Baron 440 – 26″ Wide Grill, Total Grilling Area = 570 Sq. Inches
  • Broil King Baron 550 – 32″ Wide Grill, Total Grilling Area = 750 Sq. Inches
  • Broil King Regal 400 – 26″ Wide Grill, Total Grilling Area = 630 Sq. Inches
  • Broil King Regal 500 – 32″ Wide Grill, Total Grilling Area = 825 Sq. Inches

Build Quality and Materials

I’ve yet to inspect the Broil King pellet grills in person, so I’m having to judge the build quality on the specifications and details available on these units. What I will note is these are heavy pellet grills, especially for their segment. For instance, the Broil King pellet grills weight between 135 and 160 lbs! The reason for this is because the Baron grills are made from 1.4mm (16 gauge) steel and the Regal grills are made from 2mm (14 gauge) steel. While obviously using thicker steel than the average pellet grill does increase weight, it also has several associated benefits. For instance, while a heavier grill may require more effort to move around, once its in position it will be more stable. I do also think Broil King has done a good job with the large 8″ wheels with adjustable feet on the other side to provide stability while in use.

Broil King Baron 550 Pellet Grill
I do believe the Broil King Baron 550 is good value for a large 32″ pellet grill at under a thousand dollars: Image – BBQGuys.comOpens in a new tab.

The use of thicker steel plate also means these pellet grills will be better able to withstand corrosion over time from cooking and from the elements. Another benefit of using thicker steel is these grills will be better able to hold in their heat. There is also quite a bit of stainless steel used on these Broil King pellet grills. For instance, the grease drip tray, heat deflector and pellet firepot are all thick gauge stainless steel. Again, this is a feature not commonly found on pellet grills positioned/priced as mid-range products.

The Broil King Pellet Firepot and Ash Removal

When I first saw the promotional video from Broil King above, their pellet firepot/ash removal solution definitely stood out to me. While pellet grills are very convenient you do still have to clean a pellet grill of ash from time to time. How frequently you have to get an ash/shop vac into the base of the grill depends on a couple of factors. First, have you been doing short/hot cooks or long ‘low and slow’ cooks. Typically, for quick/average cooking times with hot dogs/burgers etc, you will need to clean out a pellet grill after 3-4 cooks. With long cooks, you may need to clean out the pellet grill after each one. However, the pellet firepot design/ash management system in the Broil King pellet grills should reduce how often you need to get out the ash vac.

Broil King Pellet Grill Ash Management System
The rotating agitator in the base of the pellet firepot makes for an easy/convenient ash management system: Image – broilkingbbq.com

On the front of the Baron and Regal pellet grills is a slider which can be operated even when the grill is hot with the included tool. By moving the slider back and forth it can rotate the agitator in the base of the firepot to let the ash fall down into the draw below. Camp Chef on their SmokePro and Woodwind pellet grills have a slide valve which lets the ash drop down into a removable steel cup. Its a very effective and convenient means of ash removal, however, its also patented. Therefore, Broil King had to come up with a different solution for ash removal. I while I think Camp Chefs solution is good, I actually think Broil King’s ash management solution is even better.

WiFi/Bluetooth Controllers

Both the cheaper Baron and more expensive Regal pellet grills have WiFi/Bluetooth controllers. I’m not sure as yet whether these are true PID controllers, as I’m waiting to hear feedback from Broil King on that one. I’m also not sure on the full functionality of the smartphone app. As I discuss in my Traeger WiFire vs Camp Chef Connect post, there are differences between the features provided by different pellet grill manufacturers. However, both control panels appear bright and easy to read. The rotating temperature dial on the Regal pellet grills would be my preference, but both controllers appear easy to use.

Broil King Regal Pellet Grill Controller
I personally prefer the rotating dial of the Regal pellet grill controller, though the Baron controller is equally as easy to read: Image – broilkingbbq.com

Both the Baron and Regal pellet grill controllers have two meat probe ports which is nice to have. What I particularly like about the Broil King displays are the dedicated sections on the screen to show the meat probe sensor temperatures. On several other pellet grill controllers, such as the first generation Traeger Pro Controller you had to press a button to see the temp of the meat prob. However, with the Broil King displays its always on show, so you can quickly look down to see everything is going to plan. Its also a nice touch to have angled the displays upwards so you don’t have to dip down to see whats going on. Furthermore, both the Baron and Regal controllers feature three quick temperature setting buttons. There is a 225-degree smoking setting, a 350-degree roasting setting and a grilling/searing setting at 600 degrees.

Cast Iron Cooking Grids

Both the Baron and Regal pellet grills come with cast iron cooking grids, which again is not a feature you will commonly find on many pellet grills. Most other grills use either chrome-plated steel, porcelain plated steel or stainless steel racks on the premium pellet grills. However, the benefit with cast iron cooking grids is superior heat retention. Therefore, as the Broil King pellet grill range has a high maximum temperature setting of 600 degrees, along with the cast iron cooking grids that provides these pellet grills with the ability to successfully sear your meat, fish or vegetables.

Broil King Pellet Grill Cast Iron Grids
The cast-iron grids on the Broil King Baron and Regal will help these pellet grills to properly sear your food: Image – broilkingbbq.com

I also like how the cast iron cooking grids on both the Baron and Regal pellet grills are reversible with each side suited to a different function. You have the pointed side to give you the classic grill mark look on your steaks and burgers. On the other side of the grids, there are groves which as stated in the video above can capture juices/fats and vapourise them back into the food as its cooks. Its this attention to detail and effort which has gone into the design of these grills which makes me believe that Broil King will be a significant player in the pellet grill market in the coming years.

Pellet Hopper Capacities

Where the Baron and Regal pellet grills do differ is in their BBQ wood pellet hopper capacities. Both versions of the Baron feature an 18lb pellet hopper, where both versions of the Regal pellet grills feature a 22lb pellet hopper. With the 18lb pellet hopper on the Baron units that will still provide you with many hours of continuous cooking/smoking. However, the larger 22lbs hoppers found the Regal models do have a clear benefit. BBQ pellets come in 20lbs bags. Therefore, there can be a couple of pounds still in the hopper as the grill is running and you can still fit in a full bag of pellets. Its just a bit more convenient over the smaller 18lb hopper.

Broil King Pellet Hopper Capacities
The Baron pellet grills feature an 18lb pellet hopper whereas the Regal grills feature a larger 22lb pellet hopper: Image – broilkingbbq.com

All of the Broil King pellet grills have a pellet release door on the back of the hopper. This means its easier to change from one pellet flavour to the next. However, it importantly also makes it easy to empty out any unused wood pellets before you put the pellet grill into storage. You should not leave wood pellets in the hopper as over time they will absorb moisture from the air and expand. This can potentially lead to an auger blockage.

Rotisserie Kit

Another notable feature that sets the Broil King pellet grills apart from the competition is their Rotisserie Kit. If you wish to roast a couple of chickens the Rotisserie Kit will help you to produce some of the best results possible. The Rotisserie Kit is included on the Regal models but not on the Baron units. Though the Rotisserie Kit will fit into the Baron pellet grills, you just have to purchase it as an optional extra. On the back of the Regal pellet grills, there are also some additional hooks to store the Rotisserie Kit when not in use.

Broil King Rotisserie Kit
The Rotisserie Kit is included on Broil King Regal models and available as an optional extra on Baron units: Image – broilkingbbq.com

Broil King Baron and Regal Pellet Grill Reviews

I’m personally very impressed with these pellet grills from Broil King. However, I’m yet to see these grills in person and test their capabilities. Therefore, I like to add in owner video reviews into my posts when I can find them. The written reviews for both the Baron and Regal grills appear to be generally very positive on BBQGuys.comOpens in a new tab.. However, I’m yet to find a well-round owner video review to include in this post. What I have come across is a good comparison video from the Tin Man YouTube channel discussing the differences between the Baron and Regal grills.

This video does a good comparison of the different features on the Broil King Baron and Regal pellet grills.

The video above does a good job in comparing the Baron and Regal pellet grills. For instance, another notable difference which I forgot to mention above is the chimneys. Where the Baron vents horizontally the Regal uses a chimney stack with a ‘Roto-Draft Damper’. What this means is on the Regal you have more control over how quickly/easily smoke leaves the grill. With the included tool you can adjust the Roto-Draft Damper while the grill is running. You wouldn’t obviously want to touch the damper with your hands while the grill is running unless you wanted a third-degree burn.

Conclusions On The Broil King Baron and Regal Pellet Grills

I’m genuinely very impressed with these pellet grills from Broil King. In terms of features and material choices, these grills are proper competition for other grills in the practical pellet grill class. If I was being picky I would have hoped that ‘Broil King’ would have added a feature to let the flames from the pellet fire through the grease/drip tray so you could flame broil. This is found on several Camp Chef and Pit Boss grills, and I think its something Broil King should consider in the future, especially considering their namesake. However, the grills as they are I think are still an excellent first attempt at a pellet grill which they should be proud of. The ash management solution is a stand-out feature along with the cast-iron racks, 600-degree maximum temperature and rotisserie kit.

That’s it! Thanks for reading, I hope you found this overview of the Broil King Baron and Regal pellet grills interesting. As I stated above you can read reviews on these pellet grills over at BBQGuys.comOpens in a new tab. where they have some excellent deals and finance options. If you are interested in other makes/models of pellet grills please browse my wood pellet grill/smoker guide. 🙂

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Chris - PelHeat

Hi, I’m Chris. I started PelHeat.com back in 2007. This website is intended to be an educational resource on how pellets are made and their various uses. I hope you find the information useful.

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